Gutter and precast panel incorporating the same

ABSTRACT

A gutter embedded into a structure to collect moisture that forms on the surface of the structure. The gutter forms a substantially flush engagement with the surface of the structure, and includes a fluid redirecting surface that coaxes the fluid angularly toward a reservoir for capture and collection of the fluid. One or more anchoring portions may be included to extend away from the gutter to further promote a secure connection between the gutter and the structure. The gutter may be made from a one piece elongate body of extruded material, and may further include a planar face portion to facilitate engagement with the surface of the structure. In one form, the gutter can be formed into a wall or related panel.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. patentapplication Ser. No. 10/771,179, filed Feb. 3, 2004 (FUU 0030 PA), whichapplication claims the benefit of U.S. Provisional Application SerialNo. 60/444,478 filed Feb. 3, 2003.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to a fluid drainage gutter, thefabrication of precast or tilt-up panels or other cast-in-placestructures incorporating fluid drainage gutters, and structuresincorporating such elements.

[0003] Many residential and commercial construction methods involve theuse of concrete structures. Precast panels, for example, are integral toconstruction processes where a concrete wall (or panel) is cast in placewithin a structure or where the panel is cast on a horizontal slab orrelated panel-forming surface and tilted-up into place. In the tilt-upapproach, concrete forms are arranged on a flat casting surface in theshape and dimension of the desired tilt-up panel, then filled withconcrete. When the concrete cures, the panel and the form are separatedand the panel is tilted up into a preferred, typically vertical,orientation, where it can be joined to structural frames or otherpanels. In other approaches, precast panels are cast in a manufacturingfacility and shipped to the job site, or the concrete wall is cast inplace.

SUMMARY OF THE INVENTION

[0004] The present inventors have recognized a need for improvements inpre-cast panel forming systems and in various components of concretewall systems. For example, the present inventors have recognized a needfor addressing drainage issues associated with precast panels. While theimprovements introduced by the present invention have particularapplicability in the tilt-up construction process, pre-cast constructionprocess or cast-in-place concrete structures, the inventors alsoenvision the improved drainage enabled by the present invention to besuitable to other wall types.

[0005] The present invention provides a gutter that can be formed intothe surface of a panel (such as a wall panel) such that excess moisture(including rain, condensation or the like) is directed to a reservoirwithin the gutter. According to a first aspect of the present invention,a gutter configured to fit substantially within a wall is disclosed. Thegutter includes an upper and lower gutter portion configured to form asubstantially flush fit with a generally planar surface of the wall, areservoir configured to fit within the wall behind a plane defined bythe upper and lower gutter portions, and a fluid redirecting surfacedisposed between the upper gutter portion and the reservoir such thatmoisture accumulating on at least one of the wall-engaging portion or aportion of the surface of the wall situated above the gutter is coaxedinto the reservoir along the fluid redirecting surface. In the presentcontext, the term “substantially” is utilized to represent the inherentdegree of uncertainty that may be attributed to any quantitativecomparison, value, measurement, or other representation. As such, itrefers to an arrangement of elements or features that, while in theorywould be expected to exhibit exact correspondence or behavior, may inpractice embody something slightly less than exact. The term alsorepresents the degree by which a quantitative representation may varyfrom a stated reference without resulting in a change in the basicfunction of the subject matter at issue.

[0006] Optionally, the fluid redirecting surface is shaped to define aCoanda surface such that fluid traveling down the fluid redirectingsurface from the upper gutter portion (or from the wall above the uppergutter portion when the wall is placed in a substantially upright,vertical position) clings to the fluid redirecting surface for aconsiderable distance, even though that surface departs from a generallyvertical direction formed by the surface of the wall. By clinging to thefluid redirecting surface under the Coanda effect, the fluid is morelikely to collect in the reservoir when it does eventually separate fromthe surface. In an alternative shape, the fluid redirecting surface canform a faceted interface with the upper gutter portion such that a moreabrupt change in fluid flowpath along the gutter's cross-sectionalprofile is formed. The gutter may further include an anchoring portionextending from one or more of the upper gutter portion, lower gutterportion, reservoir or fluid redirecting surface. In one form, theanchoring portion extends away from the generally planar surface of thewall.

[0007] While the gutter may be made from an easily-formable material, ina preferred embodiment, it is made from a plastic material, such aspolyvinyl chloride (PVC), high density polyethylene (HDPE) or the like.In addition, the cross-sectional profile of the gutter is such that thegutter can be formed from an extrusion process. Moreover, the gutter canbe of unitary (i.e., one-piece) construction, such as those formed bythe aforementioned extrusion process. In another option, the gutterfurther includes a drain port disposed in the reservoir, whileadditionally, a tube can be connected to the drain port to convey thefluid accumulating in the reservoir to another location. In one form,the upper gutter portion extends to include a face portion extendingfrom the fluid redirecting surface, while the lower gutter portionextends to include a face portion extending from the reservoir. In thisway, the gutter can be placed within the wall so that the face portionsformed by the extensions of the upper and lower gutters can form asubstantially flush fit with the outer surface of the wall, although itwill be appreciated that even without the extending face portions, theupper and lower gutter can form a substantially flush fit with the wallouter surface. The aforementioned anchoring portion can be made toextend each of the face portions. While the gutter can be formed intoany size (depending on the desired use), a few particular dimensionshave been found to be especially appropriate for conventional-sizedwalls. For example, the depthwise dimension of the gutter's reservoir ispreferably less than one inch, and more preferably approximatelythree-fourths of an inch. Similarly, the heightwise dimension of thereservoir is preferably less than one inch, and more preferablyapproximately one-half of an inch. The fluid redirecting surface isangled relative to the generally planar surface of the wall, where theangle formed is approximately between 30° and 75° as measured clockwisefrom the plane of the wall outer surface. The gutter may further includea plug that can be used close off the end of the reservoir. In this, aswell as the remainder of the disclosure, it is noted that terms like“preferably,” “preferred,”, “commonly,” and “typically” or the like arenot utilized herein to limit the scope of the claimed invention or toimply that certain features are critical, essential, or even importantto the structure or function of the claimed invention. Rather, theseterms are merely intended to highlight alternative or additionalfeatures that may or may not be utilized in a particular embodiment ofthe present invention.

[0008] According to another aspect of the invention, a gutter configuredto be integrally formed into a precast panel is disclosed. The gutter isconfigured such that upon curing of the panel and its placement into agenerally upright position, the gutter defines a portion of an outersurface of the generally upright panel to enable moisture forming on atleast a portion of the surface thereof to be collected in the gutter. Aspreviously discussed, the gutter defines a unitary structure comprisinga substantially planar face portion, a reservoir fluidly coupled to theface portion, and a fluid redirecting surface disposed between the faceportion and the reservoir.

[0009] According to yet another aspect of the invention, a wall assemblymade up of at least a panel (i.e., wall) and one or more gutters formedinto the panel is disclosed. The panel is defined by an outward-facingsurface and an inward-facing surface, with the one or more guttersformed into at least one of the panel surfaces. The configuration of thegutter is similar to those previously discussed, including at least theaforementioned upper gutter portion, reservoir and fluid redirectingsurface. In situations where two or more gutters are included in thepanel, the gutters are arranged to be in fluid communication with oneanother, such as through the use of a tube as previously discussed. Thegutter (or gutters) placed in the panel can be oriented such that whenthe panel is placed in a generally upright position, the gutter slopesalong its substantial longitudinal dimension. The reservoir can beconfigured to include a drain port disposed adjacent a lower end of thesloped gutter to facilitate draining.

[0010] According to still another aspect of the invention, a guttercomprising an extrudable cross-sectional profile is disclosed. Theextrudable cross-section profile defines an upper and gutter portion, afluid containing reservoir and a fluid redirecting surface extendingfrom the upper gutter portion. The fluid redirecting surface isconfigured such that when the gutter is arranged in a generally uprightposition so that the upper gutter portion is above the lower gutterportion, fluid present at the upper gutter portion is coaxed into thereservoir along the fluid redirecting surface. The upper and lowergutter portions together define a face plane of the gutter, where suchface plane can be subsequently formed into a wall or panel to besubstantially co-planar the wall's outer surface.

[0011] According to another aspect of the invention, a method ofremoving moisture from a precast panel is disclosed. The method includesconfiguring the precast panel as previously discussed with a panel intowhich a gutter (with at least one of the aforementioned upper gutterportion, lower gutter portion, reservoir and fluid redirecting surface)may be placed, placing the precast panel in a substantially uprightposition, exposing the precast panel to a source of moisture such thatmoisture forms at least on the surface of the panel that includes thegutter, and collecting at least a portion of the formed moisture intothe reservoir. Optionally, a drain port can be disposed in the reservoirsuch that the collected moisture may be drained therefrom, while a tubemay be included to convey the collected fluid. In another option, thepanel may include a plurality of the gutters, where at least two of thegutters may be placed in fluid communication with one another throughthe tube.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0012] The following detailed description of specific embodiments of thepresent invention can be best understood when read in conjunction withthe following drawings, where like structure is indicated with likereference numerals and in which:

[0013]FIG. 1 is an illustration of the cross sectional profile of afluid drainage gutter according to one embodiment of the presentinvention;

[0014]FIG. 2 is an illustration of the cross sectional profile of afluid drainage gutter according to an alternative embodiment of thepresent invention;

[0015]FIG. 3 is an illustration of a precast structure incorporating afluid drainage gutter according to one embodiment of the presentinvention; and

[0016]FIG. 4 is an illustration of an end portion of a fluid drainagegutter according to one embodiment of the present invention.

DETAILED DESCRIPTION

[0017] Referring initially to FIGS. 1 and 2, examples of two suitablecross sectional profiles of a fluid drainage gutter 10 according to thepresent invention are illustrated. Specifically, the gutter 10 includesan upper gutter portion 12 and a lower gutter portion 14 (each with asubstantially planar face portion 20), a fluid redirecting surface 30, afluid collection and transfer reservoir 40, and one or more anchoringportions 50. The gutter 10 is illustrated as installed along a facesurface 60 (also referred to as face) of a precast structure 70 (alsoreferred to as a wall or panel). As can be seen from the figure, gutter10 and face surface 60 of precast structure 70 are generally co-planarwith one another along plane 65, such that a substantially flush fit isformed between them. Even though upper and lower gutter portions 12, 14are shown as including face portion 20, it will be appreciated that theupper gutter portion 12 need not include the face portion 20 to promotea secure connection between the gutter 10 and the precast structure 70.Similarly, lower gutter portion 14 need not include the part of the faceportion 20 that extends below the bottom of reservoir 40. For example,even in a configuration (not shown) where there is no face portion 20substantially beyond the uppermost part of the fluid redirecting surface30, the upper gutter portion 12 still forms an interface between thegutter 10 and precast structure 70. Moreover, in the case of precast andrelated tilt-up panels, the upper and lower gutter portions 12, 14(which includes face portion 20 when such is present, as describedabove) define upper and lower slab contacting portions (where the slabis the casting surface upon which a panel or wall is formed). Together,the upper and lower gutter portions 12, 14 define a face plane of thegutter 10 that is configured to be substantially co-planar with the facesurface 60 of precast structure 70, as shown along plane 65.

[0018] Referring with particularity to FIG. 1, the generally curvilinearnature of fluid redirecting surface 30 is such that the fluid 80 formingon the upper gutter portion 12 or the face 60 above gutter 10 willexhibit the Coanda effect by clinging to the fluid redirecting surface30 at least long enough so that when the fluid 80 does separate (if atall) from the surface of the gutter 10, the placement of the reservoir40 is such that it will capture any separating fluid 80. Referring withparticularity to FIG. 2, the more faceted shape of fluid redirectingsurface 30 would promote separation of fluid 80 from planar face portion20 of upper gutter portion 12 earlier than the more curved surface ofthe embodiment of FIG. 1, but still configured such that the fluid 80forming on the upper gutter portion 12 or the face 60 above gutter 10drops into reservoir 40. When the precast structure 70 is placed in agenerally vertical orientation (or has at least a significant verticalcomponent to such orientation), water or another fluid 80 on the face 60of the precast structure 70 tends to move downwardly under the effect ofgravity along the face 60 and upper gutter portion 12, as indicatedgenerally by the directional flow indicator 90. The presence of thegutter 10 at a suitable location along the face 60 aids in collectionand diversion of the fluid 80. Specifically, fluid 80 moving down theplanar face portion 20 of upper gutter portion 12 and face 60 of theprecast structure 70 tends to follow the profile of the fluidredirecting surface 30, passing into the reservoir 40 of the gutter 10.

[0019] As will be appreciated by those practicing the present invention,the profile of the fluid redirecting surface 30, the size of the fluidtransfer reservoir 40, and other dimensions of the gutter 10 will dependupon the particular fluid drainage demands at hand. For example, thegutter 10 illustrated in FIGS. 1 and 2, where the height dimension ofthe entire gutter 10 is about 2.75 inches (7 cm) and the remainingcomponents are illustrated to scale, represents a design suitable forfluid flow rates associated with relatively heavy condensation of wateron the face 60. Indeed, the present invention is well suited for usewhere condensation is likely to be prevalent on the interior walls of astructure, e.g., where high humidity levels are present in the enclosedinterior of the structure.

[0020] The gutter 10 is cast into the structure 70, along the face 60,by positioning the gutter within a conventional casting form (not shown)with the planar face portion 20 of the upper and lower gutter portions12, 14 engaging the forming surface against which the structure 70 iscast. For example, in the tilt-up context, the gutter 10 would bepositioned within a panel form such that the face portion 20 engages thepanel-forming slab upon which the panel 70 is cast. Of course, provisionis made for sealing the ends of the gutter to prevent the passage ofcasting material into the reservoir 40.

[0021]FIGS. 3 and 4 illustrate suitable positioning of a plurality ofgutters 10 in a precast structure 70 according to one embodiment of thepresent invention. As is illustrated, a plurality of gutters 10 may bepositioned along a common vertical projection on the face 60. Theposition and number of gutters 10 in the structure 70 will again dependupon the specific fluid drainage demands at issue. While the presentembodiment shows gutters 10 deployed in both upper and lower segments offace 60, it will be appreciated that the precise gutter number andlocation can be made to vary, and that all such configurations arewithin the scope of the present invention. The gutters 10 can beoriented to slope along the gutter's longitudinal dimension, andrelative to the vertical dimension of the structure 70. This has theeffect of encouraging transfer of the fluid from a remote end of thegutter 10 and toward an opposing (vertically lower) end, therebypromoting the passage of fluid that collects in the reservoir 40 into atube 100 that can either drain excess fluid away from structure 70, orconnect numerous gutters 10 together as shown. In either configuration,tube 100 extends to a location suitable for the disposal of fluid. Forexample, where the structure 70 comprises a panel, the tube 100 mayextend between adjacent panels 70 to the exterior of the structureformed by the panels. Drain plugs 102 may be included and formed of anymaterial designed to maintain structural integrity with prolongedexposure to water or the particular fluid at issue. The plugs 102 aredisposed at the low end of the gutter 10, and should also be configuredto conform to the dimensions of the reservoir 40, as well as form atight seal at the end of the fluid reservoir 40 and form a drain portthrough which the drainage tube 100 passes. Foamed materials, e.g., afoamed cylindrical plug, are often suitable for such plug functions.Referring with particularity to FIG. 3, the use of fluid drainage tubes100 in transferring fluid from one gutter 10 to another is depicted. Inmany instances, for example where an obstruction exists in the precaststructure 70, it may be necessary to interrupt gutters 10 along asubstantially horizontal dimension of a structure 70 and connect thegutters 10 with a drainage tube 100. In another configuration, thegutters 10 can be made to partially overlap, as shown in the upper partof the structure 70 in FIG. 3. As shown, the tubes 100 can fluidlyconnect the adjacent gutters 10 together. This configuration worksespecially well when the gutters 10 are sloped such that the tube 100connects lowermost portion of the vertically higher gutter 10 to theuppermost portion of the vertically lower gutter 10. In a variation (notshown) of the overlap configuration depicted in the figure, the tubes100 need not be used to fluidly connect the overlapping gutters 10. Inthis situation, overflow from reservoir 40 from the uppermost gutter 10can spill over lower gutter portion 14 and the face 60 of structure 70until it encounters the overlapped segment of upper gutter portion 12 ofthe adjacent gutter 10.

[0022] The gutter 10 and its various components may be formed from anyof variety of suitable materials including, but not limited to,plastics, metals, resins, fibrous composites, and combinations thereof.The gutter 10 may be fabricated in any suitable manner, through (forexample) extrusion, injection molding, thermoforming or the like. In oneform, the gutter 10 may be formed through a conventional extrusionprocess and, as such, defines an extrudable cross sectional profile. Forthe purposes of defining and describing the present invention, it isnoted that a structural member defines an extrudable cross sectionalprofile if respective cross sections of the member, taken along alengthwise or widthwise axis of the member, each define substantiallyidentical dimensions. In which case, the member defining the extrudableprofile may be produced by an extrusion process where a semi-softmaterial (such as the aforementioned plastic) is forced through theorifice of an extrusion die to produce a continuously formed piecehaving a cross-sectional shape defined by the orifice or related shapingmembers downstream of the orifice. A structural member having anextrudable cross-sectional profile may also include portions along itsaxis that are subject to post extrusion cutting, drilling, bending,deforming or similar post-extrusion operations.

[0023] Having described the invention in detail and by reference tospecific embodiments thereof, it will be apparent that modifications andvariations are possible without departing from the scope of theinvention defined in the appended claims. More specifically, althoughsome aspects of the present invention are identified herein as preferredor particularly advantageous, it is contemplated that the presentinvention is not necessarily limited to these preferred aspects of theinvention.

What is claimed is:
 1. A gutter configured to fit substantially within awall, said gutter comprising: an upper gutter portion and a lower gutterportion, each configured to form a substantially flush fit with agenerally planar surface of said wall; a reservoir configured to fitwithin said wall behind a plane defined by said upper and lower gutterportions; and a fluid redirecting surface disposed between said uppergutter portion and said reservoir such that moisture accumulating on atleast one of said upper gutter portion or a portion of said surface ofsaid wall situated above said upper gutter portion is coaxed into saidreservoir along said fluid redirecting surface.
 2. The gutter of claim1, wherein said fluid redirecting surface is cooperative with at leastone of said upper gutter portion or said surface of said wall situatedabove said upper gutter portion to define a Coanda surface.
 3. Thegutter of claim 1, wherein said fluid redirecting surface is cooperativewith at least one of said upper gutter portion or said surface of saidwall situated above said upper gutter portion to define a facetedsurface relative thereto.
 4. The gutter of claim 1, further comprisingan anchoring portion extending from at least one of said upper gutterportion, lower gutter portion, reservoir or fluid redirecting surface.5. The gutter of claim 4, wherein said anchoring portion extends awayfrom said generally planar surface of said wall.
 6. The gutter of claim1, wherein said gutter comprises a plastic material.
 7. The gutter ofclaim 1, wherein said gutter defines an extrudable cross-sectionalprofile.
 8. The gutter of claim 1, wherein said gutter is of unitaryconstruction.
 9. The gutter of claim 1, further comprising a drain portdisposed in said reservoir.
 10. The gutter of claim 9, furthercomprising a tube in fluid communication with said reservoir throughsaid drain port.
 11. The gutter of claim 1, wherein said upper gutterportion comprises a substantially planar face portion extending fromsaid fluid redirecting surface.
 12. The gutter of claim 11, wherein saidlower gutter portion further comprises a substantially planar faceportion extending from said reservoir.
 13. The gutter of claim 12,further comprising an anchoring portion extending from each of saidsubstantially planar face portions.
 14. The gutter of claim 1, wherein adepthwise dimension of said reservoir is less than one inch.
 15. Thegutter of claim 14, wherein a depthwise dimension of said reservoir isapproximately three-fourths of an inch.
 16. The gutter of claim 14,wherein a heightwise dimension of said reservoir is less than one inch.17. The gutter of claim 16, wherein a heightwise dimension of saidreservoir is approximately one-half of an inch.
 18. The gutter of claim1, wherein said fluid redirecting surface is angled relative to saidgenerally planar surface of said wall.
 19. The gutter of claim 18,wherein said angle is between approximately 30° and 75°.
 20. The gutterof claim 1, further comprising a plug configured to be disposed along atleast one end of said reservoir to define a closure thereto.
 21. Agutter configured to be integrally formed into a precast panel such thatupon curing of said panel and placement of same into a generally uprightposition, said gutter defines a portion of an outer surface of saidgenerally upright panel to enable moisture forming on at least a portionof the surface thereof to be collected in said gutter, said gutterdefining a unitary structure comprising a substantially planar faceportion, a reservoir fluidly coupled to said face portion, and a fluidredirecting surface disposed between said face portion and saidreservoir.
 22. A wall assembly comprising: a panel defined by anoutward-facing surface and an inward-facing surface; and at least onegutter formed into at least one of said surfaces of said panel, saidgutter comprising: an upper gutter portion configured to form asubstantially flush fit with a generally planar surface of said wall; areservoir configured to fit within said wall behind a plane defined bysaid upper gutter portion and said surface of said wall; and a fluidredirecting surface disposed between said upper gutter portion and saidreservoir such that moisture accumulating on at least one of saidwall-engaging portion or a portion of said surface of said wall situatedabove said upper gutter portion is coaxed into said reservoir along saidfluid redirecting surface.
 23. The wall assembly of claim 22, whereinsaid at least one gutter comprises a plurality of gutters.
 24. The wallassembly of claim 23, wherein at least two of said plurality of guttersare in fluid communication with one another.
 25. The wall assembly ofclaim 24, further comprising a tube coupled to said plurality of guttersto establish said fluid communication therebetween.
 26. The wallassembly of claim 22, wherein said at least one gutter is placed in saidpanel such that when said panel is placed in a generally uprightposition, said gutter slopes along its substantial longitudinaldimension.
 27. The wall assembly of claim 22, further comprising a plugdisposed along at least one end of said reservoir.
 28. A guttercomprising an extrudable cross-sectional profile, said extrudablecross-section profile defining: an upper gutter portion and a lowergutter portion that together defining a face plane of said gutter; afluid containing reservoir; and a fluid redirecting surface extendingfrom said upper gutter portion, away from said face plane of saidgutter, to said fluid containing reservoir, wherein said fluidredirecting surface is configured such that upon orientation of saidface plane of said gutter in a substantially vertical position, fluidpresent at said upper gutter portion is coaxed into said reservoir alongsaid fluid redirecting surface.
 29. A method of removing moisture from aprecast panel, said method comprising: configuring said precast panel tocomprise: a substantially planar layer defined by an outward-facingsurface and an inward-facing surface; and at least one gutter formedinto at least one of said surfaces of said panel, said guttercomprising: an upper gutter portion configured to form a substantiallyflush fit with a generally planar surface of said wall; a reservoirconfigured to fit within said wall behind a plane defined by said uppergutter portion and said surface of said wall; and a fluid redirectingsurface disposed between said upper gutter portion and said reservoirsuch that moisture accumulating on at least one of said upper gutterportion or a portion of said surface of said wall situated above saidupper gutter portion is coaxed into said reservoir along said fluidredirecting surface; placing said precast panel in a substantiallyupright position; exposing said precast panel to a source of moisturesuch that moisture forms on said at least one of said surfaces of saidpanel that includes said gutter; and collecting at least a portion ofsaid formed moisture into said reservoir.
 30. The method according toclaim 29, further comprising providing a drain port in said reservoirsuch that said collected moisture may be drained therefrom.
 31. Themethod according to claim 30, further comprising fluidly connecting atube to said drain port.
 32. The method according to claim 31, furthercomprising configuring said panel to comprise a plurality of saidgutters.
 33. The method according to claim 32, wherein at least two ofsaid plurality of said gutters are in fluid communication with oneanother through said tube.